Brassiere having a foam padded underwire

ABSTRACT

An underwire brassiere and breast cup for use in the underwire brassiere. The breast cup provides improved comfort for the wearer by isolating the support wire from the skin of the wearer. Particularly the support wire is positioned along an outer side of a laminated foam core. The laminated foam core can be shaped to have an embossed ridge projecting toward the inner side of the foam core, in a region mirroring the location of the support wire.

FIELD OF THE INVENTION

The present disclosure generally relates to apparel, particularly brassieres. More particularly, the present disclosure relates to brassieres having supportive underwire.

BACKGROUND OF THE INVENTION

Brassieres have long been part of women's daily attire. To increase support under, or along the lower periphery of brassiere cups, rigid wires have been added. Brassieres having these wires are often referred to as “underwire” brassieres. Often an underwire brassiere will include a pair of U-shaped wires, one for each respective breast cup. Alternatively, a single wire may span the bottom of both cups.

While the rigidity of an underwire brassiere provides improved support, there are also disadvantages. For example, the narrow cross-section of the support wire of the brassiere can produce discomfort due to relatively sharp pressure points. The wire's rigidity can also cause discomfort during movement. Friction between the wire and the materials of the brassiere can cause the wire to become exposed over time. Exposed wires can poke the wearers skin or snag on the wearer's clothing.

A variety of techniques have been attempted to increase the comfort of underwire brassieres, with varied levels of success. Thus, there remains a need for an underwire brassiere having improved comfort that maintains the relatively high degree of support for which underwire brassieres are known.

SUMMARY OF THE INVENTION

The present disclosure is directed to an improved construction for a brassiere having a support wire. The support wire can be disposed on the outside of a molded cup in order to increase comfort. Further, the molded cup may provide a padded ridge in the region opposite the support wire.

A first aspect of this disclosure is a breast cup for a brassiere. An exemplary breast cup may include a molded cup having an interior laminated fabric, an exterior laminated fabric, and at least one foam layer between the interior and exterior laminated fabrics. The interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded cup. The molded cup may further comprise a first raised portion adjacent to a lower peripheral edge of the molded cup. The first raised portion can extend toward an inner side of the molded cup. The exemplary breast cup can also include a support wire disposed along the lower peripheral edge of the molded cup. The support wire is configured to be positioned outwardly of the exterior laminated fabric.

A second aspect of this disclosure is a brassiere. The brassiere includes a pair of breast cups connected to each other by a bridge or central gore. Each breast cup includes a portion of a torso band attached to an end thereof, opposite the bridge. Each breast cup comprises an interior laminated fabric, an exterior laminated fabric, and at least one foam layer between the interior and exterior laminated fabrics. The interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create a molded core. The molded core may further comprise a first raised portion adjacent to a lower peripheral edge thereof. The first raised portion can extend toward an inner side of the molded core. The exemplary breast cup can also include a support wire disposed along the lower peripheral edge of the molded core and positioned outwardly of the exterior laminated fabric. The first raised portion and the support wire's location combine to improve comfort for the wearer.

These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments, when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and still other objects and advantages of the present invention will be more apparent from the following detailed explanation of embodiments of the invention in connection with the accompanying drawings.

FIG. 1 shows a perspective view of an exemplary brassiere according to this disclosure.

FIG. 2 shows a front view of an exemplary breast cup according to this disclosure.

FIG. 3 shows a back view of an exemplary breast cup according to this disclosure.

FIG. 4 shows a cut-away view of the exemplary breast cup of FIGS. 1-3 along line IV-IV shown in FIG. 3.

FIG. 5 shows a detailed cut-away view of an exemplary encased support wire according to the present disclosure.

FIG. 6 shows across section of a molded core according to a second embodiment.

FIG. 7 shows a cross section of a molded core according to a third embodiment.

DETAILED DESCRIPTION

Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, product or component aspects or embodiments and vice versa.

As used herein, the terms “inside,” “inner,” “interior,” and “back” are used to reference elements of a breast cup that are relatively positioned toward the skin of a wearer. On the other hand, the terms “outside,” “outer,” “exterior,” and “front” are used to reference elements of a breast cup that are relatively positioned in a direction away from the skin of a wearer.

Turning to the figures, FIG. 1 shows an exemplary brassiere 100 comprising a pair of breast cups 120. The breast cups 120 are connected together with a central gore, or bridge 150. A torso strap 130 may extend from the lateral sides 122 of each breast cup 120. The respective torso straps 130 may combine to encircle the torso of a wearer. Conventional adjustable fasteners (not shown) may be affixed at the ends of the respective torso straps 130 opposite the breast cups 120. The respective torso straps 130 may be replaced by a single continuous torso band (not shown). Optionally, adjustable shoulder straps 140 may connect to the top edge 124 of each breast cup 120 and connect to the torso strap 130 of the corresponding breast cup 120.

FIG. 2 shows a close up view of the front of an exemplary breast cup 120. The breast cup 120 may comprise an outermost fabric 250. The outermost fabric 250 is preferably sewn only to the periphery of the breast cup 120 and has an unattached portion over a central portion of the breast cup 120. The resulting unattached portion helps to conceal a support wire 300 disposed behind the outermost fabric 250. The outermost fabric 250 may be formed of a nylon/spandex blend, or any other suitable fabric, so the outermost fabric 250 provides a pleasing appearance and feel to the brassiere 100.

FIG. 3 shows a close up view of the back of an exemplary breast cup 120. In a preferred embodiment, the innermost layer of the breast cup 120 may comprise an interior laminated fabric 205 formed as part of a molded core 200 (see FIG. 4). Interior laminated fabric 205 is a fabric intended to be laminated to form the molded core 200. The interior laminated fabric 205 may comprise, for example, polyester, or a polyester/spandex blend. In an exemplary embodiment, the molded core 200 comprises a first embossed ridge 230 projecting from the inner side of the breast cup 120. The first embossed ridge 230 is located along the lower peripheral portion 126 of the breast cup 120 or layers thereof. The first embossed ridge 230 is configured to correspond with the location of a support wire 300 (see FIG. 4).

As best seen in FIG. 4, each breast cup 120 comprises a multi-layer construction. Each breast cup 120 may comprise a molded core 200. Preferably, the molded core 200 includes an interior laminated fabric 205, an exterior laminated fabric 210, and foam layers 215, 220 disposed between the interior laminated fabric 205 and the exterior laminated fabric 210. While FIG. 4 shows two foam layers 215, 220, the invention is not limited to the use of two foam layers. The molded core 200 is formed by laminating the foam layers 215, 220 between the interior laminated fabric 205 and the exterior laminated fabric 210 using a heated bullet/bubble mold or other processes as known in the art.

According to one embodiment, the foam layers 215, 220 may comprise polyurethane, polyester, or polyether. In an exemplary embodiment, the thickness of the foam layers 215, 220 may be between about % and about ½ inches prior to molding. The thickness of the foam layers 215, 220 and the spacing between a male (bullet) and a female (bubble) cast of a molding machine can be adjusted to provide a finished molded core 200 with the desired thickness, density, and rigidity.

Continuing with FIG. 4, a support wire 300 is configured to be attached to the outside of the molded core 200. The support wire 300 is preferably constructed from either a metallic or a rigid polymer material. The support wire 300 preferably has a relatively flat cross-section and may be bent into an arcuate shape. The support wire 300 preferably extends from the lateral side 122 of each breast cup 120, along the lower peripheral portion 126 of the breast cup 120 and ends at the central edge 128 of the breast cup 120 adjacent the bridge 150.

In the embodiment shown in FIG. 4, and detailed in FIG. 5, the support wire 300 is wrapped between one or more fabric plies 305, 310. The one or more fabric plies 305, 310 may be separate from one another. In a preferred embodiment, the inner ply 305 may comprise a first material, while the outer ply 310 comprises a second, different, material. The inner ply 305 is likely to rub against the support wire 300. Therefore the first material may be selected to be relatively strong and highly resistant to abrasion. On the other hand, the second material can be selected to help furnish a smooth appearance to front of the brassiere 100.

Preferably the inner ply 305 and the outer ply 310 are not directly attached to the support wire 300. The inner and outer fabric plies 305, 310 may be wrapped around the support wire 300 in an inverted U-shaped configuration, with the free ends of the at least one fabric ply 305, 310 being turned inwardly before being stitched onto the outside of the molded core 200. The support wire 300 is held in place along the lower periphery of the outside of the molded core 200 by first stitching 315. Preferably stitching 315 begins from the outside direction, through the inner and outer plies 305, 310, and into, but not completely through, the molded core 200.

The outermost fabric 250 (described above) can also be seen in the cross-section of FIG. 4. The embodiment of FIG. 4 also includes an optional cup liner 260 that may be disposed between the outermost fabric 250 and the molded core 200. In a preferred embodiment, the cup liner 260 comprises 100% polyester. The cup liner 260 shields the molded core 200 from view, helping to prevent visibility of “yellowing” of the molded core 200 that can occur in laminated foam layers 215, 220 after a series of launderings. When the fabric layers (e.g. 205, 250) used to form the brassiere 100 are of a dark color (e.g. black), the cup liner 260 may not be required: “yellowing” is already masked by the dark fabric.

As shown in FIG. 3, the molded core 200 of the present disclosure includes a first embossed ridge 230 that extends arcuately along the lower peripheral portion 126 of each breast cup 120. As show in FIG. 4, preferably, the first embossed ridge 230 projects inwardly toward the wearer. The first embossed ridge 230 mirrors the position where the support wire 300 resides along the outside of the molded core 200.

The first embossed ridge 230 provides supplemental cushioning to the support wire 300. In the embodiment of FIG. 4, an area comprised of foam layers 215, 220, which has increased thickness, defines the first embossed ridge 230.

In one embodiment, a single layer of foam 215 is used to form cup 120. The first embossed ridge 230 can be created by providing the male cast of a molding machine with a groove corresponding to the first embossed ridge 230. When the single layer of foam 215 is pressed in the mold, the area of the first embossed ridge 230 will be compressed less than the remainder of the molded core 200.

In a second embodiment, as shown in FIG. 4, both a first layer of foam 215 and a second layer of foam 220 may be used. The first layer of foam 215 may be configured to be coextensive with the entire breast cup 120, providing padding therefore. For example, the first layer of foam 215 may be between about ⅛ and about ¼ inches thick. The second layer of foam 220 may be configured to primarily correspond only with the lower peripheral portion 126 of the molded core 200. The second layer of foam 220 may be between about ¼ and about ⅜ inches thick. Use of the second layer of foam 220, substantially dedicated to the creation of the first embossed ridge 230, will allow for an increase in height and density of the first embossed ridge 230. To facilitate proper placement in the molding machine, the second layer of foam 220 may have a perimeter that corresponds to the perimeter of the first layer of foam 215. When this is the case, the second layer of foam 220 may have central portions removed that would otherwise correspond to the majority, or central portion, of the finished molded core 200.

Visual enhancement of the first embossed ridge 230 may also be desirable. Second stitching 245 on either side, and along substantially the entire length, of the first embossed ridge 230 can provide a visual delineation on the back of each breast cup 120.

FIG. 6 shows another embodiment of a molded core 200 according to the present disclosure. In this embodiment, a recessed channel 235 is formed in the molded core 200 during the molding process. The recessed channel 235 corresponds to the shape and placement of the support wire 300 in the finished breast cup 120. The recessed channel 235 may be between about 3/16 inches and about 7/16 inches wide. The recessed channel 235 is sized to accommodate the support wire 300 and the at least one fabric ply 305, 310. In one embodiment, the recessed channel 235 is dimensioned to maintain the support wire 300 substantially flush with the outer surface of the molded core 200. This substantially flush surface arrangement contributes to improve the appearance of the brassiere 100 by helping to hide the support wire 300 behind the outermost fabric 250. The recessed channel 235 corresponds to the first embossed ridge 230, each on an opposite side of the molded core 200. The recessed channel 235 may be formed by providing a female portion of a mold with a projection to correspond with a groove in a male portion of the mold. The projection will form the recessed channel 235 and the groove will allow the formation of the first embossed ridge 230.

FIG. 7 shows another embodiment of a molded core 200 according to the present disclosure. Molded core 200 of the instant embodiment comprises a second embossed ridge 240 extending toward the outer side of the molded core 200. The second embossed ridge 240 is disposed opposite to the first embossed ridge 230. The first and second embossed ridges 230, 240 combine to form an area of increased foam thickness in the finished molded core 200. The thickness of foam provided by first and second embossed ridges 230, 240 provide even more cushioning compared to first embossed ridge 230 alone.

Although the above disclosure has been presented in the context of exemplary embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents. 

We claim:
 1. A breast cup for a brassiere comprising: a) a molded cup, the molded cup comprising: a. an interior laminated fabric; b. an exterior laminated fabric; and c. at least one foam layer, wherein the interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded cup, the molded cup further comprising a first raised portion adjacent to a lower peripheral portion thereof, the first raised portion extending toward an inner side of the molded cup; and b) a support wire, wherein the support wire is disposed along the lower peripheral portion of the molded cup and disposed outwardly of the exterior laminated fabric.
 2. The breast cup according to claim 1, wherein the molded cup further comprises a second raised portion along the lower peripheral portion of the molded cup, the second raised portion extending toward an outer side of the molded cup such that the first and second raised portions correspond to one another.
 3. The breast cup according to claim 1, wherein the molded cup further comprises a recessed channel along an outer side of the molded cup opposing the first raised portion, the recessed channel configured to receive the support wire.
 4. The breast cup according to claim 1, wherein the first raised portion provides an area of increased thickness along the lower peripheral portion of the molded cup.
 5. The breast cup according to claim 1, wherein the at least one foam layer comprises: a first foam layer substantially coextensive with the interior laminated fabric and the exterior laminated fabric; and a second foam layer disposed adjacent to the lower peripheral portion of the molded cup, the second foam layer providing additional material for the formation of the first raised portion.
 6. The breast cup according to claim 1, further comprising at least one fabric ply encasing the support wire.
 7. The breast cup according to claim 6, wherein the at least one fabric ply comprises a plurality of separate plies, wherein, each of said plurality of separate plies is wrapped around the support wire without attachment to the support wire.
 8. The breast cup according to claim 1, further comprising an outer fabric disposed outwardly of the exterior laminated fabric and disposed outwardly of the support wire.
 9. The breast cup according to claim 8, further comprising a cup liner disposed between the exterior laminated fabric and the outer fabric.
 10. The breast cup according to claim 1, wherein the support wire comprises a substantially flat, metallic or rigid plastic material.
 11. A brassiere comprising: a) a pair of breast cups, each breast cup comprising: a. a molded core, the molded core comprising: i. an interior laminated fabric; ii. an exterior laminated fabric; and iii. at least one foam layer, wherein the interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded core, the molded core further comprising a first raised portion adjacent to a lower peripheral edge thereof, the first raised portion extending toward an inner side of the molded core; and b. a support wire, wherein the support wire is disposed along the lower peripheral portion of the molded core and disposed outwardly of the exterior laminated fabric; b) a bridge or gore attached between a center of each breast cup; and c) a torso band, respective ends of the torso band attached to underarm lateral side of a respective breast cup.
 12. The brassiere according to claim 11, wherein the molded core further comprises a second raised portion along the lower peripheral portion of the molded core, the second raised portion extending toward an outer side of the molded core such that the first and second raised portions correspond to one another.
 13. The brassiere according to claim 11, wherein the molded core further comprises a recessed channel along an outer side of the molded core opposing the first raised portion, the recessed channel configured to receive the support wire.
 14. The brassiere according to claim 11, wherein the first raised portion provides an area of increased thickness along the lower peripheral portion of the molded core.
 15. The brassiere according to claim 11, wherein the at least one foam layer comprises: a first foam layer coextensive with the interior laminated fabric and the exterior laminated fabric; and a second foam layer disposed adjacent to the lower peripheral portion of the molded core, the second foam layer providing additional material for the formation of the first raised portion.
 16. The brassiere according to claim 11, further comprising at least one fabric ply encasing the support wire.
 17. The brassiere according to claim 16, wherein the at least one fabric ply comprises a plurality of separate plies, each of said plurality of separate plies is wrapped around the support wire without attachment to the support wire.
 18. The brassiere according to claim 11, wherein each breast cup further comprises an outer fabric disposed outwardly of exterior laminated fabric and disposed outwardly of the support wire.
 19. The brassiere according to claim 18, wherein each breast cup further comprises a cup liner disposed between the exterior laminated fabric and the outer fabric.
 20. The brassiere according to claim 11, wherein the support wire comprises a substantially flat, metallic or rigid plastic material. 